Engine Block Skirt Stiffener

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	303-1246 Engine Spreader Bar TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1250 Seal Installer, Rear Main TKIT-2006UFFLM
Courtesy of FORD MOTOR COMPANY	303-1531 Installer, Front Crank Seal and Damper
Courtesy of FORD MOTOR COMPANY	303-1634 Lift Eyes (2) TKIT-2014D-FL_ROW TKIT-2014D-ROW3
Courtesy of FORD MOTOR COMPANY	303-335 (T88T-6701-A) Installer, Front Cover Oil Seal TKIT-1988-F TKIT-1988-FLM
Floor Crane
Mounting Stand
Flat-Bladed Screwdriver
Vise
Vise Jaw Protectors

Materials 

Name	Specification
Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP	WSS-M2C946-A
Motorcraft ® High Performance Engine RTV Silicone TA-357	WSE-M4G323-A6
Motorcraft ® Orange Concentrated Antifreeze/Coolant VC-3-B	WSS-M97B44-D

• 1.
  
  
  NOTE: If the engine block skirt stiffener is not installed, aligned and the bolts tightened to minimum specification within 10 minutes, the sealant must be removed and the sealing area cleaned.

  Apply a 4.5 mm (0.18 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine block skirt stiffener.

  Material: Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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• 2.
  
  

  • 1.
    
    Position the oil seal.

  • 2.
    
    Install the engine block skirt stiffener.

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• 3.
  
  

  • 1.
    
    Install the bolts finger tight.

  • 2.
    
    Tighten the 2 bolts.

    Torque:

    Stage 1: 35 lb.in (4 Nm)

    Stage 2: Loosen: 360 °

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• 4.
  
  

  • 1.
    
    Using a straight edge, align the rear face of the engine block skirt stiffener to the rear face of the engine block, flush or up to 0.250 mm (0.01 in) underflush.

  • 2.
    
    Using a straight edge, align the machined bosses on the left side of the engine block skirt stiffener to the machined bosses on the left side of the engine block flush or within 0.280 mm (0.011 in) of flush.

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• 5.
  
  
  NOTE: If the engine block skirt stiffener bolts minimal torque is not completed within 10 minutes of sealant application, or if final torque is not met within 60 minutes of sealant application the parts must be removed and the sealant must be removed and the sealing area cleaned.

  Tighten the engine block skirt stiffener bolts.

  Torque:

  Stage 1: 35 lb.in (4 Nm)

  Stage 2: 18 lb.ft (24 Nm)

• 6.
  
  Install the oil pump and the bolts.

  Torque:

  Stage 1: 89 lb.in (10 Nm)

  Stage 2: 45 °

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• 7.
  
  Install the oil pump drive chain.

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• 8.
  
  Install oil pump drive chain guide and bolts.

  Torque: 89 lb.in (10 Nm)

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• 9.
  
  

  • 1.
    
    Install the oil pump drive chain tensioner and bolt.

    Torque: 89 lb.in (10 Nm)

  • 2.
    
    Remove the pin.

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• 10.
  
  
  NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For removal and installation of the RH side the triangle marks are used.

  • 1.
    
    Install the RH timing chain with the single colored links aligned with the triangle  timing marks on the VCT units.

  • 2.
    
    Install the double colored links so they straddle the timing mark on the crankshaft sprocket.

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• 11.
  
  Install the RH timing chain guide and bolts.

  Torque: 89 lb.in (10 Nm)

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• 12.
  
  Install the RH timing chain tensioner arm.

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• 13.
  
  Slide the tensioner cylinder out of the RH timing chain tensioner housing.

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• 14.
  
  
  NOTE: Use vise jaw protectors or cover the jaws of the vise with clean shop towels to prevent damage to the surface of the tensioner ratchet mechanism.

  Mount the flat machined surfaces on the end of the tensioner cylinder into a vise.

  • 1.
    
    Using a flat-bladed screwdriver apply light downward pressure on the end of the tensioner ratchet mechanism. Use the General Equipment: Vise Use the General Equipment: Vise Jaw Protectors Use the General Equipment: Flat-Bladed Screwdriver

  • 2.
    
    Rotate the screwdriver clockwise approximately one turn.

  • 3.
    
    An audible click will be heard when the tensioner ratchet mechanism locks into place.

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• 15.
  
  

  • 1.
    
    Slide the tensioner cylinder into the RH timing chain tensioner housing to the fully retracted position.

  • 2.
    
    Install a retaining pin into the hole in the housing to lock the cylinder in the retracted position.

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• 16.
  
  

  • 1.
    
    Position the RH timing chain tensioner with the end of the tensioner correctly engaged to the tensioner arm.

  • 2.
    
    Install the bolts.

    Torque: 89 lb.in (10 Nm)

  • 3.
    
    Remove the pin.

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• 17.
  
  Install new engine front cover gaskets.

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• 18.
  
  Lubricate and install a new oil gallery seal (6G068).

  Material: Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

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• 19.
  
  
  NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
  NOTE: The engine front cover must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

  Apply a 9 mm (0.35 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the cylinder block skirt-to-cylinder block joint and the cylinder head-to-cylinder block joint areas as indicated.

  Material: Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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• 20.
  
  
  NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
  NOTE: The engine front cover must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

  Apply a 4.5 mm (0.18 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the inner bolt bosses.

  Material: Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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• 21.
  
  Install the engine front cover and the fasteners.

  Torque:

  Stage 1: Tighten bolts 1 thru 11 to: 18 lb.ft (24 Nm)

  Stage 2: Tighten bolts 12 thru 13 to: 35 lb.ft (48 Nm)

  Stage 3: Tighten bolts 14 thru 21 to: 18 lb.ft (24 Nm)

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• 22.
  
  Lubricate the engine front cover bore with clean engine oil.

  Material: Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

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• 23.
  
  Using the special tools, install the new crankshaft front oil seal. Use Special Service Tool: 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal., 303-1531 Installer, Front Crank Seal and Damper.

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• 24.
  
  Lubricate the crankshaft front seal inner lip with clean engine oil.

  Material: Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

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• 25.
  
  Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.

  Material: Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

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• 26.
  
  Using the special tools, install the crankshaft pulley. Use Special Service Tool: 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal., 303-1531 Installer, Front Crank Seal and Damper.

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• 27.
  
  
  NOTE: Use a universal pulley holder (such as an OTC 4754, or equivalent).

  Using a universal pulley holder, install and tighten a new crankshaft pulley bolt.

  Torque:

  Stage 1: 166 lb.ft (225 Nm)

  Stage 2: Loosen: 360 °

  Stage 3: 26 lb.ft (35 Nm)

  Stage 4: 270 °

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• 28.
  
  
  NOTE: Installation of new seals is only required if damaged seals were removed.

  Using the special tools, install new spark plug tube seals. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

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• 29.
  
  Install a new gasket.

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• 30.
  
  
  NOTE: If the valve cover is not installed and the fasteners tightened within 10 minutes, the sealant must be removed and the sealing area cleaned.

  Apply an 8 mm (0.31 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to-cylinder head joints.

  Material: Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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• 31.
  
  Install the valve cover and tighten the bolts.

  Torque: 89 lb.in (10 Nm)

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• 32.
  
  Install the oil level indicator.

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• 33.
  
  
  NOTE: Installation of new seals is only required if damaged seals were removed.

  Using the special tools, install new spark plug tube seals. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

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• 34.
  
  Install a new gasket.

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• 35.
  
  
  NOTE: If the valve cover is not installed and the fasteners tightened within 10 minutes, the sealant must be removed and the sealing area cleaned.

  Apply an 8 mm (0.31 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to-cylinder head joints.

  Material: Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

Courtesy of FORD MOTOR COMPANY

• 36.
  
  Install the valve cover and tighten the bolts.

  Torque: 89 lb.in (10 Nm)

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• 37.
  
  Install a new oil pump seal.

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• 38.
  
  
  NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
  NOTE: The oil pan must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

  • 1.
    
    Apply a 4.5 mm (0.18 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the sealing surface of the new oil pan.

    Material: Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

  • 2.
    
    Apply a 9 mm (0.35 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to-cylinder block joint areas on the new oil pan.

    Material: Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

  • 3.
    
    Inspect the crankcase ventilation passages to make sure they are not blocked by any sealer applied.

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• 39.
  
  Install the new oil pan and the bolts.

  Torque: 89 lb.in (10 Nm)

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• 40.
  
  Install the new TC oil return tube-to-engine block gasket.

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• 41.
  
  Install a new TC oil return tube O-ring seal and then lubricate with clean engine oil.

  Material: Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

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• 42.
  
  Install the TC oil return tube, then install and tighten the TC oil return tube bolts.

  Torque: 89 lb.in (10 Nm)

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• 43.
  
  Install the new TC oil return tube-to-engine block gasket.

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• 44.
  
  Install a new TC oil return tube O-ring seal and then lubricate with clean engine oil.

  Material: Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

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• 45.
  
  Install the TC oil return tube, then install and tighten the TC oil return tube bolts.

  Torque: 89 lb.in (10 Nm)

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• 46.
  
  
  • Lubricate the inside and the outside diameter of the grommet with clean engine coolant.

    Material: Motorcraft ® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

  • Install the grommet so it is flush with the rear of the coolant pump housing.

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• 47.
  
  
  NOTE: Verify the front cover dowel pins are aligned to the coolant pump and that the coolant pump is fully seated prior to installing the fasteners.
  • Using a new gasket, install the coolant pump and the fasteners.

    Torque:

    Fasteners 1-7:

    Stage 1: 89 lb.in (10 Nm)

    Stage 2: 45 °

  • Torque:

    Fastener 8: 18 lb.ft (24 Nm)

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• 48.
  
  Inspect and replace any ignition coil-on-plugs that have rubber boots with cracks, rips or tears.

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• 49.
  
  

  • 1.
    
    Install the ignition coil-on-plugs.

  • 2.
    
    Install and tighten the ignition coil-on-plug stud bolts.

    Torque: 53 lb.in (6 Nm)

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• 50.
  
  

  • 1.
    
    Install the vacuum tube assembly onto the engine and attach the retainers.

  • 2.
    
    Install the vacuum control solenoid bolts.

    Torque: 62 lb.in (7 Nm)

  • 3.
    
    Connect the vacuum tube quick release coupling. Refer to: Quick Release Coupling .

  • 4.
    
    Connect the vacuum hose and clamp to the TC.

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• 51.
  
  Connect the vacuum hose and clamp to the TC.
  • Attach the vacuum hose retainers.

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• 52.
  
  Install the engine wiring harness onto the engine.
  • Connect the engine wiring harness electrical connectors and attach the retainers.

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• 53.
  
  Connect the engine wiring harness electrical connectors and attach the retainers.

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• 54.
  
  Connect the engine wiring harness electrical connectors and attach the retainers.

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• 55.
  
  Connect the engine wiring harness electrical connectors and attach the retainers.

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• 56.
  
  Connect the oil control solenoid electrical connector and attach the wiring harness retainers.

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• 57.
  
  
  • Attach the wiring harness retainers.
  • Connect the fuel pump electrical connector.
  • Install the wiring harness ground terminal to the rear of the RH cylinder head and install the stud bolt.

    Torque: 89 lb.in (10 Nm)

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• 58.
  
  Install the ground terminal to the rear of the RH cylinder head stud bolt and install the nut.

  Torque: 89 lb.in (10 Nm)

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• 59.
  
  
  • Install the wiring harness ground terminal to the rear of the LH cylinder head and install the stud bolt.

    Torque: 89 lb.in (10 Nm)

  • Connect the KS wiring harness connector and attach the retainer.

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• 60.
  
  Install the engine appearance cover bracket and the bolts.

  Torque: 97 lb.in (11 Nm)

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• 61.
  
  Install a new oil cooler gasket.

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• 62.
  
  Install the oil cooler and the bolts.

  Torque: 89 lb.in (10 Nm)

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• 63.
  
  

  • 1.
    
    Position the bracket with heater hose and install the nuts.

    Torque: 89 lb.in (10 Nm)

  • 2.
    
    Connect the heater hose and clamp.

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• 64.
  
  Install the bracket and the nuts.

  Torque: 89 lb.in (10 Nm)

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• 65.
  
  Install the A/C compressor and the bolts.

  Torque: 18 lb.ft (25 Nm)

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• 66.
  
  Install the accessory drive belt tensioner, the idler pulley and the bolts.

  Torque:

  Tensioner: 18 lb.ft (25 Nm)

  Idler pulley: 18 lb.ft (24 Nm)

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• 67.
  
  
  • NOTE: Do not tighten coolant pump pulley bolts at this time.

    Install the coolant pump pulley bolts.

  • Install the idler pulley and the bolt.

    Torque: 35 lb.ft (48 Nm)

  • Install the generator, the bolt and the nut.

    Torque: 35 lb.ft (48 Nm)

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• 68.
  
  Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.

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• 69.
  
  Make sure the accessory drive belt is correctly seated on all pulleys.

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• 70.
  
  Tighten the coolant pump pulley bolts.

  Torque: 89 lb.in (10 Nm)

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• 71.
  
  Install the auxiliary coolant pump and the bolts.

  Torque: 62 lb.in (7 Nm)

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• 72.
  
  
  • Connect the auxiliary coolant pump electrical connector.
  • Connect the coolant hoses and clamps.

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• 73.
  
  Install the engine mount and the new bolts.

  Torque: 57 lb.ft (77 Nm)

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• 74.
  
  Install the engine mount-to-cylinder block bracket and the new bolts.

  Torque: 57 lb.ft (77 Nm)

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• 75.
  
  Using a floor crane, remove the engine from the mounting stand. Install Special Service Tool: 303-1634 Lift Eyes (2)., 303-1246 Engine Spreader Bar. Use the General Equipment: Floor Crane Use the General Equipment: Mounting Stand

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• 76.
  
  Lubricate the crankshaft rear seal lips with clean engine oil.

  Material: Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

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• 77.
  
  
  NOTE: The crankshaft rear seal and retainer plate must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

  Apply a 4.5 mm (0.18 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the crankshaft rear seal and retainer plate.

  Material: Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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• 78.
  
  
  • Position the special tool onto the end of the crankshaft. Use Special Service Tool: 303-1250 Seal Installer, Rear Main.
  • Slide the new crankshaft rear seal and retainer plate onto the tool and into the installed position.

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• 79.
  
  Install the crankshaft rear seal retainer plate bolts. Remove Special Service Tool: 303-1250 Seal Installer, Rear Main.

  Torque: 89 lb.in (10 Nm)

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• 80.
  
  

  • 1.
    
    Install the CKP sensor and the bolt.

    Torque: 89 lb.in (10 Nm)

  • 2.
    
    Connect the CKP sensor electrical connector.

  • 3.
    
    Position the CKP sensor electrical connector insulator.

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• 81.
  
  Install the crankshaft sensor ring and the engine-to-transmission spacer plate.

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• 82.
  
  

  • 1.
    
    Position the flexplate on the crankshaft.

  • 2.
    
    Install the bolts then rundown the bolts one turn at a time in sequence shown until the flexplate is snug against the rear face of the crankshaft.

  • 3.
    
    Final tighten the bolts in sequence shown.

    Torque: 59 lb.ft (80 Nm)

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• 83.
  
  Install the engine into the vehicle. Refer to: Engine .